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Safety and HealthBasic Foundations Series 719

710719LP

LESSON PLANS

Safety and Health719

Instructor SupportMaterial:

Lesson Plans

710719LP

How to Use These Lesson PlansThese Lesson Plans are very structured and detailed to be as helpful as possible to afirst time instructor or trainer. Modify the Lesson Plans to meet your own specific needs.

The Lesson Plans contain:• Brief restatements of the material in the text along with cues to ASK: questions, DISCUSS: a

topic, or SHOW: a figure. The text is large so that you can read it from a distance.

• Important words in bold type. These include both technical terms whose meanings the studentsneed to know and any words that you may want to locate quickly in the text.

Before teaching the class:• Read the lessons to be covered and the corresponding Lesson Plans.

• Write your own notes for additional discussion or activities in the blank spaces of the LessonPlans.

Keep in mind:• The most effective teaching method is:

• Tell the students what will be covered on the topic.

• Present the information.

• Tell the students what they just learned (and how they will be expected to show that theyknow it.)

• The more reaction and participation you can get from your students, the better.

• Remind the students that their success is a direct result of their efforts.

• Technical material is rarely learned the first time; it takes repetition. Involve more physical sensesto make learning happen faster and last longer. For example draw and look at diagrams, see andhandle physical objects.

• Students generally get more out of a course, evaluating it and their instructor more highly, whenthe instructor is enthusiastic about the teaching materials.

Table of Contents

Chapter One Introduction to Safety and Health............................................ 5

Chapter Two Government Safety and Health Regulations..........................25

Chapter Three Personal Protective Equipment.............................................. 47

Chapter Four Chemical Safety..................................................................... 65

Chapter Five Tool Safety.............................................................................87

Chapter Six Material Handling................................................................ 111

Chapter Seven Working Safely with Machinery..........................................135

Chapter Eight Working Safely with Electricity.......................................... 157

Chapter Nine Electrical Equipment Safety................................................ 175

Chapter Ten Fire Safety............................................................................195

Chapter Eleven Protecting Your Health........................................................ 219

Chapter Twelve A Safe Work Environment...................................................241

© Copyright 1992, 2001, 2009 by Schoolcraft Publishing

All rights reserved, including those of translation.

No part of this material may be reproduced in any form or by any means, electronic or mechanical, including photocopying, recording, or by any infor‐mation storage and retrieval system. Schoolcraft Publishing does not, by publication of data in this book, ensure to anyone the use of such data againstliability of any kind, including infringement of any patent. Publication of any data in this book does not constitute a recommendation of any patent orproprietary right that may be involved.

16-1

Safety and Health — 719

Lesson Planfor

Chapter OneIntroduction to Safety and Health

TOPICS Text Page LessonPlan Page

Responsibility for Safety 4 7Your Company's Safety Program 4 8Unsafe Acts and Unsafe Conditions 6 11Recognizing Hazards 10 15Health Hazards 10 16Types of Accidents 13 20Accident Investigation 14 20Handling Emergencies 14 21Safety Off the Job 16 23

Schoolcraft Publishing

Safety and Health — 719

Lesson Planfor

Chapter OneIntroduction to Safety and Health

Objectives: Upon the completion of this chapter, the studentshould be able to:

• Define the terms accident and hazard.• Name and define the four main types of hazards.• List and define various types of accidents.• Compare meanings of the terms unsafe act and unsafe condition.• Name the three ways in which a toxic substance can enter your body.• List ways in which a company must plan for emergencies.• Tell the main reason for prompt accident investigation.


Activity Text Paragraph

Responsibilityfor Safety (p. 4)

Your employer is responsible—by law—for providingyou with a safe place to work.

Your employer must:

• select safe equipment

• identify and control hazards

• establish safety rules and procedures.

1.01

Not all the responsibility for your safety rests with youremployer. You must arrive at work in good physicalcondition, do your job as you were trained to do it, andfollow the safety rules and procedures.

1.02

An accident is an unexpected event resulting in injury,illness, or property damage.

A hazard is a condition that could cause an injury.

For example, a high-pressure steam line is a hazard, butit cannot be eliminated from the plant. But, a shaky lad-der is a hazard that can be eliminated.

Accidents are often caused by conditions that no one hasyet recognized as hazardous.

1.03

Safety and Health 719 7



• Part of your responsibility for safety is to report anyconditions that may cause accidents.

Safety experts agree that a hazardous condition usuallycauses many close calls before it causes a major acci-dent.

• One person may slip on an oily floor, hit his headon the cement, and have permanent vision prob-lems.

• The next person slips in the same place and onlygets his pants dirty.

1.04

Your Compa‐ny's SafetyProgram (p. 4)

The safety program includes training, methods of com-municating problems and changes of policy to allemployees, and the committees or management struc-ture that create the company's safety policies.

1.05

Safety committees.

Not all companies or plants have safety committees.Safety committees can include representatives frommost or all departments and shifts, both supervisors andnonsupervisors. The safety committee may receive allsuggestions and reports of unsafe conditions.

1.06

New employee orientation. 1.07

8 Safety and Health 719



An orientation ensures that anyone newly hired at afacility has all the basic safety information needed. Theorientation should include:

• a tour of the work area

• location of medical care

• method of reporting injuries

• location of fire and emergency equipment

• required personal protective equipment

• incentive and awards programs

• housekeeping requirements

• required inspections

• plant safety rules.

Bulletin boards/communication.

Bulletin boards, newsletters, or some other form of com-munications are used to answer questions and inform allemployees of changes in rules or conditions.

There are also some forms of information that theemployer is required to have posted at all times:

• required federal and state safety posters

• other posters

• how to obtain emergency care

1.08




• plant safety rules

• plant emergency plan and map

• list and location of all chemicals used in everydepartment.

Training.

Basic training for all employees includes:

• use of powered industrial equipment

• safe handling of chemicals

• proper lifting and carrying techniques

• first aid and CPR

• evacuation procedures for fire and weather emer-gencies

• how to read the information on signs and tags.

1.09

Each employee must be given a complete description ofhis or her specific job.

• This description must include all the hazards of thejob.

• The employee must be given specific training forthat job including all the work procedures.

The specific training for the job may include informationon any or all of the following:

1.10




• forklift and crane operation

• machine safety

• lockout/tagout procedures

• radiation, fumes, gas

• use of respirators and other protective equipment

• cutting and welding procedures

• MSDSs.

Incentive programs.

Some companies have incentive programs with awardsfor a high number of hours without any injuries.

The purpose of an incentive program is to improvesafety.

• Never fail to report an injury or unsafe condition towin an award.

1.11

Unsafe Actsand UnsafeConditions (p. 6)

In industrial safety, unsafe acts always mean undesira-ble (as well as unsafe) behavior.

An unsafe act does not necessarily result in an injury oran accident.

1.12




Safety experts estimate that there are about 300 unsafeacts committed for each one that results in an injury.

This does not mean that you are safe the first 299 timesthat you do not wear goggles when you cut metal.

• The probability that you will be hurt is the sameevery time.

• If you let yourself get into the habit of doing some-thing unsafe, it is very hard to break the habit again.

Figure 1-1 is called the accident pyramid.

SHOW: Fig. 1-1

The accident pyramid illustrates the fact that serious,disabling, or fatal injuries usually occur only after a longseries of close calls, near misses, and minor accidents.

Action to prevent serious accidents must be taken at thebottom of the pyramid.

1.13

It is your employer's responsibility to design work pro-cedures that make your job as safe as possible, to trainyou in these procedures, and to encourage you to havesafe work habits.

It is your responsibility to perform your job as you weretrained to do it.

It is also your employer's responsibility to give you theknowledge you need to recognize unsafe conditions andunsafe acts.

1.14




Unsafe acts include:

• not wearing required protective equipment

• distracting other people (teasing, horseplay)

• operating any equipment you have not been trainedin

• operating equipment outside its range

• failing to secure or store objects properly

• not warning or signalling other people or not givingthem information they need

• trying to service moving machinery

• carrying, lifting, or loading unsafely

• disabling safety devices

• using unsafe equipment

• failing to call attention to the unsafe acts of others.

Taking unsafe shortcuts or not reporting unsafe condi-tions is gambling that this unsafe act will cost you:

• nothing

• only minor inconvenience or injury

• the loss of part of your body

• the loss of the use of your legs or eyes




• the loss or your life.

Unsafe conditions.

Most of your safety responsibilities can be summed upas: do not commit unsafe acts and be alert for unsafeconditions.

SHOW: Fig. 1-2

1.15

Unsafe conditions include:

• unsafe machinery or defective tools

• dangerous work areas, surfaces, or elevations

• inadequate ventilation

• inadequate lighting

• ineffective warning and alarm systems

• unsafe clothing or ineffective protective devices

• slippery walking surfaces.

1.16

The workplace must be inspected regularly and often forunsafe conditions.

Formal inspections are usually done by supervisors, butunsafe conditions checked during an inspection are alsoconditions you should report if they occur betweeninspections.

1.17




SHOW: Fig. 1-3

Notice all the checks of fire extinguishers.

Inspections must ensure that all emergency equipment isready to use.

Inspections also check whether employees are wearingtheir required safety equipment.

Whenever you see an unsafe condition, do somethingabout it.

• If it is just a box sticking out in an aisle, move it.

• Report spills, defective wiring, slippery floors.

• Do not work with defective tools.

NOTE:If you believe that a condition presents animmediate danger to you, by law you do notneed to perform that task until the situationis corrected.

1.18

RecognizingHazards (p. 10)




ASK: What is the definition of a hazard?Answer: A hazard is a condition that could cause aninjury.

SHOW: Fig. 1-4

1.19

The four main kinds of industrial hazards are:

Electrical—Electrical hazards are everywhere in theplant.

Chemical—Explosive, flammable, toxic, and corrosivechemicals.

Mechanical—Moving machinery, gears, and work-inprogress.

Environmental—Heat, cold, noise, radiation, and fire.

1.20-1.23

Health Haz‐ards (p. 10)

Safety includes staying healthy as well as avoidinginjury. Some hazardous conditions cause illnesses thatdo not develop for years.

1.24

Toxic substances.

A substance is toxic if its presence in your body willmake you sick.

• All poisons are toxic substances.

1.25




• Substances like lead and asbestos are not chemi-cally poisonous, but cause illness because theyinterfere with the way your body works.

There are three easy ways for substances to get insidethe body:

• by breathing (inhaling)

• eating (ingesting)

• being absorbed through the skin.

SHOW: Fig. 1-5

EXTRA INFORMATION: The most common humandiseases are reactions to the substances that enter thebody through these three paths: colds (breathing), rashes(skin), and vomiting or diarrhea (eating).

Toxic substances can cause either:

• an acute (sudden) reaction, like poison gas

• a chronic (lingering) condition, like smoker'scough

• an acute disease many years later, like cancer orblack lung.

1.26

Noise.

Hearing loss is caused by noise.

1.27




• It may take years before hearing is lost due toexcessive noise.

• The governement has limited the amount of noise towhich workers can be exposed.

• Hearing loss is discussed in detail in Lesson 11.

Radiation.

Most work places do not have radiation.

If radiation is used in your job, remember:

• you will not feel or sense anything if you areexposed to radiation

• you will need a radiation detection instrument togather a reading of the exposure.

Follow the manufacturer's instructions exactly whenhandling radiation sources.

1.28

Engineering controls are changes made to the workarea, machinery, or tools to minimize employees' expo-sure to hazards.

Examples of engineering controls:

• noise barriers

• housing of radiation sources

• ventilation systems that trap and evacuate gas andfumes from the work area.

1.29




If engineering controls cannot be used to eliminate ahazard, each person must be protected by wearing per-sonal protective equipment:

• goggles

• respirators

• protective suits.

You must be trained in the use of this protective equip-ment including:

• how to wear it

• when to wear it

• how to take care of it.

1.30

Repetitive motion injuries.

One kind of hazards that we have not yet mentioned isinjury caused by motions of the body itself.

• Back injuries from improper lifting are commonand familiar to everyone.

1.31

SHOW: Fig. 1-6

Even using the proper techniques illustrated in Fig. 1-6,many repetitions of lifting can cause injury. This is anexample of repetitive motion injury.

1.32




Most repetitive motion injuries are to the hands andarms. Many tools are being redesigned to require lessgripping and twisting.

Types of Acci‐dents (p. 13)

In order to better prevent an accident, you need to knowwhat actions can cause harm.

The following identifies the various accident types:

Caught between—being pinched or squeezed

Caught in—an enclosure or grating

Caught on—a moving object, like a conveyor belt

Fall from above—from a ladder or platform

Struck by—a dropped tool, a moving forklift

Struck against—a wall or machine

Contacted by—chemical spill, hot wires

Exposed to—toxic chemicals, fumes

Strain or overexertion—from lifting or pulling.

1.33-1.35

AccidentInvestigation (p. 14)

Accident investigation. 1.36




The purpose of an accident investigation is to keep thesame accident from happening again.

The investigation is usually conducted by the first-linesupervisor of the department, who is looking for facts,not finding fault.

Most accidents have multiple causes.

• The investigation should find all conditions thatcontributed to the accident.

• Answer all questions as fully and truthfully as youcan.

Figure 1-7 shows a typical accident report form.

SHOW: Fig. 1-7

1.37

After the investigation is complete, an attempt will bemade to change the conditions that caused the accident:

• machinery may be moved

• tools my be improved

• more training may be required.

1.38

HandlingEmergencies (p. 14)




Emergencies include fires, medical emergencies,storms, and chemical spills.

1.39

In case of a fire, your facility should:

• have adequate fire extinguishers

• train employees in fire prevention basics

• have a sprinkler system in place

• have emergency maps noting fires exits, fire-fighting equipment, and gas shutoffs.

Do not become involved in a fire that endangers you.

Note where the maps, exits, equipment, and shutoffs arelocated.

1.40

Repeating emergency drills until people automaticallydo the right thing prevents panic and wild actions andhas saved many lives.

1.41

If you and your fellow employees are trained in first aidand CPR (cardiopulmonary resuscitation):

• you may some day save someone's life when themedical department cannot get there in time.

1.42

If your facility is in an earthquake, tornado, or hurricanearea, you will have evacuation drills and special storageprecautions.

1.43




“Spill training” includes safe clean-up and legal dis-posal.

• You can cause enormous problems by pouringsomething down a drain.

Do not attempt to clean up a chemical spill unless yourhave been trained to do it.

1.44

Safety Off theJob (p. 16)

Unless you have an unusually dangerous job, your chan-ces of being injured or killed triple as soon as you leavethe plant.

The most dangerous place you can be is in your car. Thesecond most dangerous place is your home.

1.45

Follow these simple rules to save lives and prevent inju-ries in automobiles.

• Wear your seat belt.

• Stay calm and attentive while driving.

• Make sure you are fine to handle the car - do nottake medicine, alcohol, or other drugs prior to driv-ing.

• Do not cut in and out of traffic.

Be alert at home for common hazards, like:

1.46




• falling

• fire.

You should be aware of safety wherever you are-work,home, or car.

1.47

Safety is not a sometimes thing. It is something youpractice every day in everything you do.

1.48



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